JP2022090545A - Anti-fogging fiber board manufacturing method and anti-fogging interior material manufacturing method - Google Patents

Abstract

To provide a manufacturing method of an anti-fogging fiber board and an anti-fogging interior material, which can suppress fogging.SOLUTION: A manufacturing method of an anti-fogging fiber board has a step to obtain a fiber board 20 formed by thermally compressing a fiber mat in which vegetable fibers and resin fibers are mixed and binding vegetable fibers 20a to each other through a thermoplastic resin 20b, and at least either one of a heating step (A) and a heating step (B). The heating step (A) is a step to heat the fiber mat at a temperature that does not exceed a melting point of the thermoplastic resin, and the heating step (B) is a step to heat the fiber board at a temperature that does not exceed the melting point of the thermoplastic resin. A manufacturing method of an anti-fogging interior material has a step C to heat the fiber board to be a substrate layer at a temperature that does not exceed the melting point of the thermoplastic resin, a step D to heat the fiber board after being subject to the step C at a temperature equal to or higher than the melting point of the thermoplastic resin, and a step to shape the fiber board in a heated state.SELECTED DRAWING: Figure 2

Description

The present invention relates to a method for manufacturing an anti-fog fiber board and a method for manufacturing an anti-fog interior material. More specifically, the present invention relates to a method for manufacturing an anti-fog fiber board using plant fiber as a reinforcing fiber, and a method for manufacturing an anti-fog interior material using the fiber board.

In recent years, as a highly rigid but lightweight base material, a fiber board having a structure in which plant fibers are bonded to each other with a thermoplastic resin (binding resin) is known. And such a fiber board is used as an interior material of a vehicle provided with a window. Further, conventionally, while various characteristics are required for interior materials, there is a requirement for fogging characteristics. For example, in a vehicle that becomes hot, various components may be volatilized, and the volatilized components may be subsequently cooled to cloud the inner surface of the glass window. Such a phenomenon is called fogging, and it is generally required to suppress fogging.
The following Patent Document 1 refers to fogging in a fiber board using plant fibers as described above.

Japanese Unexamined Patent Publication No. 2014-233769

As described above, when the presence or absence of fogging and the degree of fogging were measured for the fiber board having a structure in which plant fibers were bound to each other with a binding resin, it was found that fogging may occur at a level requiring improvement. In such a case, conventionally, it has been possible to deal with it by considering a method of not using the causative component or by substituting the causative component with another component. In this respect, the same applies to Patent Document 1. That is, when the base material layer 3 and the skin layer 5 are bonded together, fogging is prevented by not using an adhesive containing a volatile component.
However, in the above-mentioned fiber board, in order to form a fiber mat, it is necessary to utilize a causative component that can induce fogging, and it may be difficult to replace it.

The present invention has been made in view of the above circumstances, and is an anti-fog fiber board capable of suppressing fogging in the obtained fiber board and interior material while continuing the fiber mat forming method used so far. It is an object of the present invention to provide a method for producing an anti-fog interior material and a method for producing an anti-fog interior material.

That is, the present invention is as shown below.
A method for manufacturing an anti-fog fiber board to suppress fogging.
In the method for producing an antifogging fiber board of the present invention, a fiber mat in which plant fibers and resin fibers containing a thermoplastic resin are mixed is heat-compressed, and the plant fibers are bonded to each other by the thermoplastic resin. The board forming process to obtain the fiber board that is bound together,
The gist is to include at least one of the following heating steps (A) and the following heating step (B).
Heating step (A): Fiber mat heating step of heating the fiber mat at a temperature not exceeding the melting point of the thermoplastic resin Heating step (B): The fiber board at a temperature not exceeding the melting point of the thermoplastic resin. Fiber board heating step to heat In the method for producing an antifogging fiber board of the present invention, the moisture content of the fiber mat after the heating step (A) is 10% or less, and the fiber after the heating step (B). The moisture content of the board can be 10% or less.
In the method for producing an antifogging fiber board of the present invention, a cleaning step of washing the fiber mat with water can be provided before the heating step (A).
In the method for producing an anti-fog fiber board of the present invention, the temperature of the water can be set to 50 to 70 ° C.
The method for producing an antifogging fiber board of the present invention includes a drainage step of reducing the moisture content of the fiber mat to 15 to 25% under non-heating after the washing step and before the heating step (A). Can be done.

The method for producing an anti-fog interior material of the present invention is a method for producing an anti-fog interior material for suppressing fogging.
The anti-fog interior material includes a base material layer in which plant fibers are bonded to each other by a thermoplastic resin.
The heating step (C) of heating the fiber board to be the base material layer at a temperature not exceeding the melting point of the thermoplastic resin, and
The heating step (D) of heating the fiber board that has undergone the heating step (C) to a temperature equal to or higher than the melting point of the thermoplastic resin is used.
It is a gist to include a shaping step of shaping the fiber board in a heated state through the heating step (D).
In the method for producing an anti-fog interior material of the present invention, the anti-fog interior material includes a skin layer bonded to the base material layer.
Prior to the shaping step, a laminating step of laminating the fiber board in a heated state and the epidermis material to be the epidermis layer to obtain a laminate through the heating step (D) is provided.
The shaping step can be a shaping step for shaping the laminate.
In the method for producing an anti-fog interior material of the present invention, the moisture content of the fiber board after the heating step (C) can be reduced to 10% or less.

According to the method for manufacturing an anti-fog fiber board and the method for manufacturing an anti-fog interior material of the present invention, while continuing the method for forming a fiber mat that has been used so far, the obtained fiber board and interior material are fogged. Can be suppressed.

It is explanatory drawing explaining the fiber mat. It is explanatory drawing explaining the fiber board. It is explanatory drawing explaining the interior material. It is explanatory drawing explaining the manufacturing process of a fiber mat. It is explanatory drawing explaining the manufacturing process of the fiber mat following FIG. It is explanatory drawing explaining the manufacturing process of a fiber board. It is explanatory drawing of an example explaining the manufacturing process of an interior material. It is explanatory drawing of another example explaining the manufacturing process of an interior material. It is explanatory drawing explaining the evaluation method of the fogging characteristic.

Hereinafter, the present invention will be described with reference to the drawings. The matters shown here are for illustrative purposes and embodiments of the present invention, and are considered to be the most effective and effortless explanations for understanding the principles and conceptual features of the present invention. It is stated for the purpose of providing what is to be done. In this regard, it is necessary for a fundamental understanding of the invention and is not intended to show structural details of the invention beyond a certain degree, and some embodiments of the invention by description in conjunction with the drawings. It is intended to clarify to those skilled in the art how is actually embodied.

In the following, the "heating step (A)" is also referred to as the "heating step A". The same applies to the heating step (B), the heating step (C), and the heating step (D).
Further, the plant fiber 10a contained in the fiber mat 10, the plant fiber 20a contained in the fiber board 20, and the plant fiber 30a contained in the base material layer 31 of the interior material 30 are different in the process through which each material is passed, but the present application. Then, basically, it can be treated as the same thing. Similarly, the thermoplastic resin constituting the resin fiber 10b contained in the fiber mat 10, the thermoplastic resin (binding resin) 20b contained in the fiber board 20, and the thermoplastic contained in the base material layer 31 of the interior material 30. Although the process of each material is different, the resin 30b (binding resin 30b) can be basically treated as the same in the present application.

[1] Method for manufacturing anti-fog fiber board The method for manufacturing an anti-fog fiber board of the present invention includes a board forming step (R5) and a heating step A (R4) and / or a heating step B (R6). (See FIGS. 1 and 2 and FIGS. 4 and 5).

As described above, the method comprises heating step A (R4) and / or heating step B (R6). By providing the heating step A (R4) and / or the heating step B (R6), fogging can be effectively suppressed in the present invention. Although the mechanism is not clear, it is considered that the causative component that induces fogging can be removed (partially or wholly removed) by the heating step A (R4) and / or the heating step B (R6).

More specifically, for example, the resin fiber is used for the purpose of improving or improving the slippage between the resin fiber and various devices and jigs for passing the resin fiber until the resin fiber reaches the fiber mat. Lubricating components may be applied to the surface. It is considered that one form of fogging is that the lubricating component and its decomposition products volatilize according to the environment, are cooled on the window surface, the wall surface, and the like, and are deposited on the window surface, the wall surface, and the like. In particular, precipitation on the window surface is required to be suppressed because it obstructs the view. The lubricating component required for the formation of the fiber mat can be eliminated once the formation of the fiber mat is completed. Therefore, it is considered that fogging is less likely to occur by removing by the heating step A (R4) and / or the heating step B (R6).
The details of the specific lubricating component are not limited, but examples thereof include nonionic surfactants.

In the above-mentioned "board forming step (R5)", the fiber mat 10 in which the plant fiber 10a and the resin fiber 10b containing the thermoplastic resin are mixed is thermally compressed, and the plant fibers 10a (20a) heat each other. This is a step of obtaining a fiber board 20 which is bound by a plastic resin 20b (a resin obtained by melting a resin fiber 10b).
That is, the fiber board 20 thermally compresses the fiber mat 10 obtained through the mat forming step R1 for forming the fiber mat 10 in which the plant fiber 10a and the resin fiber 10b containing the thermoplastic resin are mixed. Obtainable.

The fiber mat 10 may be formed in any way. Specifically, it can be formed by using a web making device such as an air array and a card. For example, when an air array is used, the fibers are blown off by blowing air so that the plant fibers 10a and the resin fibers 10b are mixed in a desired ratio, and the fibers are deposited to a desired thickness to form a web (coarse web 11A and). 11B) can be obtained. The webs (11A and 11B) may be used as the fiber mat 10 as they are, but the laminated web (11C) obtained by stacking a plurality of webs can be used as the fiber mat 10. Further, when the laminated web (11C) is used, the laminated web (11C) can be needle punched (a needle punching machine 51 can be used) to strengthen the entanglement. Further, the obtained laminated web (11C) can be cut into a desired size and shape using a cutting machine 52 to obtain a fiber mat 10 (see FIG. 4).

The basis weight and thickness of the fiber mat 10 are not limited, but for example, the basis weight can be 400 to 3000 g / m ² , and further can be 600 to 2000 g / m ² . Further, the thickness can be 5 mm or more (usually 50 mm or less), further 8 to 40 mm, and particularly 10 to 30 mm.

The ratio of the plant fiber 10a and the resin fiber 10b in the fiber mat 10 is not limited, but when the total of the plant fiber 10a and the resin fiber 10b is 100% by mass, the plant fiber 10a is 30 to 95% by mass. Preferably, 32 to 85% by mass is more preferable, 33 to 75% by mass is further preferable, and 35 to 70% by mass is particularly preferable. Further, when the total amount of the fiber mat 10 is 100% by mass, the total amount of the plant fiber 10a and the resin fiber 10b is preferably 70% by mass or more, more preferably 80 to 100% by mass, and 85 to 100% by mass. Is more preferable, and 90 to 100% by mass is particularly preferable.

The plant fiber 10a is a fiber derived from a plant. The part of the plant body containing the plant fiber is not limited, and may be any part such as a woody part, a non-woody part, a leaf part, a stem part and a root part. Further, only a specific part may be used, or two or more different parts may be used in combination.
The fiber taken out from the plant may be used as a plant fiber as it is, or may be processed into various processes and then used as a plant fiber. Examples of various processes include letting (including letting using microorganisms, letting using enzymes, etc.), boiling, steaming, heating, drying, cutting, tapping, washing, chemical treatment, and the like. Only one of these may be used, or two or more thereof may be used in combination.

The plant species from which the plant fiber 10a is extracted are not limited, but for example, kenaf, jute hemp, Manila hemp, sisal hemp, goose bark, mulberry, mulberry, banana, pineapple, coconut palm, corn, sugar cane, bagasse, palm, papyrus, reed, esparto, etc. Examples include bagasse, wheat, rice, bamboo, coniferous trees (sugi, hemp, etc.), broadleaf trees, cotton and the like. These may be used alone or in combination of two or more. Of these, kenaf and / or jute hemp are preferred.
Kenaf is a plant that has a woody stem and is classified in the Malvaceae family. This kenaf includes hibiscus cannabinus and hibiscus sabdarifa in the scientific name, and includes red hemp, cuba kenaf, western hemp, taikenaf, mesta, bimuri, ambari hemp, and bombay hemp in the common names.
In addition, jute hemp includes corchorus capsularis (Corchorus capsularis L.) and hemp and Shinanoki family plants including corchorus capsularis (Corchorus capsularis L.) and corchorus capsularis, Nalta jute and Moroheiya.

The fiber length and diameter of the plant fiber 10a are not limited. From the viewpoint of the mechanical properties required for the obtained fiber mat 10, the fiber board 20 obtained by using the fiber mat 10, the interior material 30 obtained by using the fiber board 20, and the like, the ratio of the fiber length to the fiber diameter is It is preferably 10 to 15,000. Further, the fiber length is preferably 10 mm or more. As a result, high strength (flexural strength, flexural modulus, etc., the same applies hereinafter) can be obtained. The fiber length is more preferably 10 to 150 mm, further preferably 20 to 100 mm, and particularly preferably 30 to 80 mm.
The fiber diameter is preferably 1 mm or less, more preferably 0.01 to 1 mm, further preferably 0.02 to 0.7 mm, and particularly preferably 0.03 to 0.5 mm. In this range, high strength can be obtained in the obtained fiber board 20 and the interior material 30 using the fiber board 20. The plant fiber 10a may contain a fiber that deviates from the fiber length and the fiber diameter, but the content thereof is preferably 10% by mass (particularly 3% by volume) or less with respect to the entire plant fiber 10a.

The above fiber length means the average fiber length (the same applies hereinafter), and in accordance with JIS L1015, single fibers are randomly taken out one by one by a direct method, and the fiber length is measured on a scale to total the total. It is an average value measured about 200 fibers. Further, the fiber diameter means an average fiber diameter (the same applies hereinafter), and single fibers are randomly taken out one by one, and the fiber diameter at the center in the length direction of the fibers is measured using an optical microscope, and a total of 200 fibers are measured. It is an average value measured for a book.

On the other hand, the resin fiber 10b is a fiber that contains a thermoplastic resin and is molded into a fibrous form. The resin type constituting the resin fiber 10b is not limited, but the polyrefin resin is preferable from various viewpoints such as mechanical properties, distribution amount, cost and the like. Examples of the olefin monomer constituting the polyolefin resin include ethylene, propylene, 1-butene, 3-methyl-1-butene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene and 1-. Examples include hexene and 1-octene. Only one of these may be used, or two or more thereof may be used in combination.

Therefore, examples of the polyolefin resin include polypropylene resins such as a propylene homopolymer, a propylene / ethylene copolymer, and a propylene / 1-butene copolymer. In these polypropylene resins, 50% or more of the total number of constituent units is a resin of units derived from propylene. Further, polyethylene resins such as an ethylene homopolymer, an ethylene / 1-butene copolymer, an ethylene / 1-hexene copolymer, and an ethylene / 4-methyl-1-pentene copolymer can be mentioned. In these polyethylene resins, 50% or more of the total number of constituent units is a resin of units derived from ethylene.
The molecular weight of the polyolefin resin is not limited, but for example, the weight average molecular weight (according to the GPC method) is preferably 10,000 to 200,000, more preferably 15,000 to 100,000, further preferably 20,000 to 60,000, and particularly preferably 25,000 to 45,000.

Further, the above-mentioned polyolefin resin constituting the resin fiber 10b may be composed of only a non-modified polyolefin resin, but may contain an acid-modified polyolefin resin. When the acid-modified polyolefin resin is contained, the binding property between the melted resin fiber 10b and the plant fiber 10a can be improved, and the mechanical properties of the obtained fiber board 20 can be improved.
The acid-modified polyolefin resin is a resin in which an acid-modifying group is introduced into a polyolefin resin which is a skeleton resin. Examples of the acid-modifying group include an anhydrous carboxylic acid group (-CO-O-OC-) and a carboxylic acid group (-COOH). Only one of these may be used, or two or more thereof may be used in combination.
Further, the acid modifying group may be introduced using any compound, for example, maleic anhydride, itaconic anhydride, succinic anhydride, glutaric anhydride, adipic anhydride, maleic acid, itaconic acid, fumaric acid. It can be introduced using an acid, acrylic acid, methacrylic acid and the like. Only one of these may be used, or two or more thereof may be used in combination. Among these, maleic anhydride and itaconic anhydride are preferable, and maleic anhydride is particularly preferable.

The molecular weight of the acid-modified polyolefin resin is not limited, but for example, the weight average molecular weight (according to the GPC method) is preferably 10,000 to 200,000, more preferably 15,000 to 100,000, further preferably 20,000 to 60,000, and particularly preferably 25,000 to 45,000. The acid value (according to JIS K0070) is preferably 15 or more (usually 80 or less), more preferably 15 to 70, further preferably 20 to 60, and particularly preferably 23 to 30. Among these, in the present invention, maleic anhydride-modified polypropylene having a weight average molecular weight of 25,000 to 45,000 and an acid value of 20 to 60 is preferable.

When the resin fiber 10b contains an acid-modified polyolefin resin, the ratio of the non-modified polyolefin resin to the acid-modified polyolefin resin is not limited, but when the total of these is 100% by mass, the ratio of the acid-modified polyolefin resin is 50. It is preferably 5% by mass or less (usually 0.1% by mass or more), more preferably 0.5 to 40% by mass, further preferably 1 to 30% by mass, particularly preferably 2 to 20% by mass, and 3 to 3 to 20% by mass. 10% by mass is particularly preferable.

The fiber length and fiber diameter of the resin fiber 10b are not limited, but the ratio of the fiber length to the fiber diameter is preferably in the range of 10 to 15,000. More specifically, the fiber length is preferably 10 mm or more, more preferably 10 to 150 mm, further preferably 20 to 100 mm, and particularly preferably 30 to 80 mm.
The fiber diameter is preferably 1 mm or less, more preferably 0.001 to 1.5 mm, further preferably 0.005 to 0.7 mm, further preferably 0.008 to 0.5 mm, and 0.01 to 0.3 mm. Is particularly preferable.
The resin fiber 10b may include a resin fiber having a form outside the above-mentioned fiber length and fiber diameter. When the resin fiber 10b in an out-of-form form is contained, the content thereof is preferably 10% by mass (particularly 3% by volume) or less with respect to the entire resin fiber 10b. The method for measuring the fiber length and the fiber diameter is the same as that for the plant fiber 10a.

The fineness of the resin fiber 10b is not limited, but is preferably 15 dtex or less, for example. By suppressing the fineness of the resin fiber 10b to 15 dtex or less, it is possible to obtain a form that is more easily used as a raw material for a fiber mat. That is, it is possible to make it easier to mix the fiber with the plant fiber 10a. The fineness is further preferably 1 to 15 dtex, more preferably 3 to 11 dtex, still more preferably 4 to 10 dtex.

The resin fiber 10b may be made of only a polyolefin resin (non-modified polyolefin resin, acid-modified polyolefin resin), but may contain other thermoplastic resins. When another thermoplastic resin is contained, the amount of the other thermoplastic resin is preferably 30% by mass or less, preferably 15% by mass, when the total amount of the thermoplastic resin constituting the resin fiber 10b is 100% by mass. The following is more preferable, and 5% by mass or less is particularly preferable.

Other thermoplastic resins include modified polyolefins having no acid-modifying group (polyolefins modified by groups other than acid-modifying groups), polyester resins (aliphatic polyester resin, aromatic polyester resin), and aromatic vinyl resins. Examples thereof include (polystyrene resin), acrylic resin, polyamide resin (aliphatic polyamide resin, aromatic polyamide resin), polycarbonate resin, polyacetal resin, ABS resin and the like. Only one of these may be used, or two or more thereof may be used in combination.
Further, the resin fiber 10b may contain, for example, a bulking agent, a coloring agent, an inorganic flame retardant, or the like, in addition to the resin, if necessary.

In addition to the plant fiber 10a and the resin fiber 10b, the fiber mat 10 can include, for example, a thermal expansion capsule and other reinforcing fibers other than the plant fiber 10a. Examples of other reinforcing fibers include metal fibers, carbon fibers, glass fibers, resin fibers (resin fibers excluding the above-mentioned resin fibers 10b, for example, polyamide resin fibers, polyester resin fibers, etc.) and the like. Only one of these may be used, or two or more thereof may be used in combination.
When other reinforcing fibers are included, when the total of the plant fiber 10a, the other reinforcing fibers and the resin fiber 10b is 100% by mass, the ratio of the other reinforcing fibers is usually 50% by mass or less, which is 20% by mass. % Or less is preferable, 10% by mass or less is more preferable, and 5% by mass or less is particularly preferable. The lower limit is not limited, but can be, for example, 0.1% by mass or more.

In the board forming step R5 (see FIG. 6), the fiber mat 10 is heat-compressed as described above. That is, it is compressed while being heated. Of these, the resin fibers 10b are melted by heating to become a molten thermoplastic resin. The thermoplastic resin in the molten state is also flowed between the plant fibers 10a by compression. Then, by stopping the heating, the molten thermoplastic resin is solidified, and the fiber mat 10 becomes the fiber board 20. Therefore, the fiber board 20 is made into a plate shape by binding the plant fibers 20a to each other with a thermoplastic resin (the thermoplastic resin that binds the plant fibers 20a to each other is also referred to as a "binding resin") 20b. Is what you are doing.

As described above, the plant fiber 20a in the fiber board 20 is substantially the same as the plant fiber 10a in the fiber mat 10, but the fiber mat 10 is heated and compressed when it is processed into the fiber board 20. It differs in whether or not it has been received. Further, the binding resin 20b in the fiber board 20 is a resin obtained by solidifying the resin fibers 10b in the fiber mat 10 after being melted, and is a resin that binds the plant fibers 10a to each other. As for the details of the binder resin 20b, the description given in the resin fiber 10b can be applied except that the fiber shape is not used.

The heating temperature in the board forming step R5 is not limited, and may be a temperature at which the resin fibers 10b can be melted (particularly, a temperature equal to or higher than the melting point of the thermoplastic resin constituting the resin fibers 10b). Specifically, it is usually 150 to 280 ° C. In particular, when the resin fiber 10b is made of a non-modified polypropylene resin (which may further contain an acid-modified polypropylene resin), the heating temperature is preferably 170 to 250 ° C. The temperature is more preferably 180 to 240 ° C, and particularly preferably 190 to 230 ° C. Further, when the molten thermoplastic resin is solidified, it is preferable to cool it to about 20 to 30 ° C. This cooling may be forced cooling or may be free cooling.

The compression in the board forming step R5 can be performed at the same time as heating or separately. Even if heating and compression are performed separately, the resin fiber 10b to be the binder resin 20b is not flowed unless it is in a melted state. Therefore, the compression is usually performed in a state where the resin fiber 10b is melted. That is, even if heating and compression are performed at the same time or separately, heat compression is performed. By performing the compression in this way, the plant fibers can be more firmly bonded to each other. In addition, the thickness of the obtained fiber board 20 can be controlled. The pressure at this time is not particularly limited and can be changed according to desired characteristics, but for example, it can be 0.5 to 8 MPa, preferably 0.7 to 5 MPa, more preferably 1 to 4 MPa.
As described above, in thermal compression, heating and compression can be performed separately. If done separately, compression is usually performed before the molten thermoplastic resin is solidified. On the other hand, as a form of simultaneous pressing, a hot press (hot press machine 57, see FIG. 6) can be used. By using a hot press, the plant fibers 20a (10a) can be restrained from each other by the binding resin 20b in a state where the plant fibers 20a (10a) are compressed, so that the thickness of the obtained fiber board 20 is further reduced. be able to.

The basis weight and thickness of the fiber board 20 are not limited, but for example, the basis weight can be 400 to 3000 g / m ² , and further can be 600 to 2000 g / m ² . Further, the thickness can be 0.5 mm or more (usually 50 mm or less), and further can be 1 to 25 mm, particularly 1.5 to 10 mm.

The above-mentioned "heating step A (R4)" (see FIG. 5) is a step of heating the fiber mat 10 at a temperature not exceeding the melting point of the thermoplastic resin. That is, it can be rephrased as a fiber mat heating process. By providing this heating step A (R4), it is considered that the causative component that induces fogging is volatilized.

The heating temperature in the heating step A (R4) may be a temperature that does not exceed the melting point of the thermoplastic resin constituting the resin fiber 10b, and the specific temperature is not limited, but is preferably 50 ° C. or higher. 60 ° C. or higher is more preferable, and 70 ° C. or higher is further preferable. On the other hand, the upper limit of the temperature at the time of heating is not limited, but for example, 150 ° C. or lower is preferable, 120 ° C. or lower is more preferable, 100 ° C. or lower is further preferable, and 90 ° C. or lower is particularly preferable.
This temperature is the atmospheric temperature in the heating environment. That is, when the heating furnace 56 is used, it is the atmospheric temperature in the heating furnace 56.

Further, the heating in the heating step A (R4) is usually heating under non-pressurization. That is, it is preferable to heat in a state where no pressure is applied to the heating atmosphere from the outside. Specifically, heating in an open system, heating under an air flow, and heating in a reduced pressure environment are preferable. This is because in these environments, the volatilized causative components are easily discharged to the outside of the system.
Further, the fiber mat 10 may be heated by only one sheet, but can be heated in layers. In this case, for example, 2 to 20 sheets can be stacked and heated, 3 to 15 sheets can be stacked and heated, and 4 to 10 sheets can be stacked and heated.
The heating step A (R4) may be performed only once, or may be performed a plurality of times of two or more times.

Further, the heating time in the heating step A (R4) is not limited, but can be, for example, 15 minutes or more, 30 minutes or more, 1 hour or more, and 12 hours or more. It can be done for more than a day. On the other hand, the upper limit of the heating time is not limited, but can be, for example, one week or less, one day or less, 12 hours or less, and six hours or less. It can be 1 hour or less, and 30 minutes or less.

Further, in the heating step A (R4), it is considered that the causative component is volatilized by heating, but as a result, moisture is also volatilized from the fiber mat 10 at the same time by this heating. The fiber mat 10 usually contains at least an equilibrium moisture content or higher. The equilibrium moisture content of the fiber mat 10 varies depending on the content ratio of the plant fiber 10a (plant fiber 10a / (plant fiber 10a + resin fiber 10b)) and the environment in which the fiber mat 10 is placed, but is, for example, 4 to 13%. be. Therefore, the degree of removal of the causal substance can be indirectly known by observing the water content. From such a viewpoint, the moisture content of the fiber mat 10 after the heating step A (R4) is preferably 10% or less, more preferably 5% or less, further preferably 4% or less, and particularly less than 3%. preferable. The water content is a value calculated by "M2 / M1 × 100" when the dry mass of the fiber mat is M1 (g) and the mass of the water contained in the fiber mat is M2 (g). This moisture content can be measured using, for example, a heat-drying moisture meter.

Further, the heating step A (R4) may be performed alone, but may be accompanied by a cleaning step R2. That is, a cleaning step R2 for cleaning the fiber mat 10 with water can be provided before the heating step A (R4). By going through the cleaning step R2 involving contact between water and the fiber mat 10, it is possible to obtain a further excellent fogging suppressing effect as compared with the case where only the heating step A (R4) is performed. The mechanism is not clear, but it is considered that the causative component contained in the fiber mat 10 is transferred to water (for example, by dissolution, hydration, etc.). That is, it is considered that the causative component is transferred to water and discharged to the outside of the system together with the water, so that more causative components can be removed than the causative component that can be removed only by the heating step A (R4). However, the causative component removed by the heating step A (R4), the causative component removed by the heating step A (R4), and the causative component removed by the cleaning step R2 may be common and common. It does not have to be.

Further, the contact with the water 55 in the cleaning step R2 may be performed in any way as long as the fiber mat 10 and the water are in contact with each other. For example, it can be realized by immersing the fiber mat 10 in the water tank 54, bathing the fiber mat 10 with water, passing the fiber mat 10 through running water, and the like. Further, when the fiber mat 10 comes into contact with water, it is sandwiched between two plate-shaped net bodies 53 (wire mesh, resin net, etc.) having a retaining shape from the viewpoint of preventing the fiber mat 10 from losing its shape. Can be done. Of course, if the fiber mat 10 and water are in contact with each other, other contact methods can be used. These various contact methods may be used alone or in combination of two or more.

Further, the water to be contacted is usually liquid water, but it does not prevent it from being gaseous water. The water temperature is not limited, and can be, for example, more than -4 ° C and lower than 100 ° C, but is preferably 15 ° C or higher and 95 ° C or lower, more preferably 25 ° C or higher and 90 ° C or lower, and 35 ° C or higher and 80 ° C. The following is more preferable, and 50 ° C. or higher and 70 ° C. or lower is particularly preferable.
As the liquid to be contacted, it is possible to use other than water, but there is an advantage that the use of water does not cause a VOC problem. In addition, the working environment is better than that of organic solvents and the like, and equipment costs can be suppressed.

Further, after the cleaning step R2, the heating step A (R4) may be performed without going through another step, but the drainage step R3 can be provided if necessary. That is, each step can be performed in the order of the cleaning step R2, the drainage step R3, and the heating step A (R4). The drainage step R3 is a step of reducing the amount of water contained in the fiber mat 10 and lowering the water content of the fiber mat 10. By providing the drainage step R3, the washing effect in the washing step R2 can be obtained more reliably, and the heating time in the heating step A (R4) can be reduced. That is, the energy consumption in the heating step A (R4) can be reduced. From such a viewpoint, it is preferable that the drainage step R3 is performed under non-heating.
Further, when the drainage step R3 is provided, the moisture content reduced by the drainage step R3 is not limited, but for example, the moisture content of the fiber mat 10 after the drainage step R3 can be reduced to 50% or less, and further 5% or more. It can be 30% or less, and further 15% or more and 25% or less.

In the drainage step R3, it suffices if water can be drained from the fiber mat 10, and any drainage may be performed. For example, the fiber mat 10 containing water can be lifted and the water can be drained by dropping the water from the inside of the fiber mat 10 by its own weight. In addition, a fiber mat 10 containing water is sandwiched between two plate surfaces (for example, a non-perforated plate made of metal or resin, a perforated plate with a drain hole, etc.) to reduce the distance between the plate surfaces. Then, the water can be drained by compressing the fiber mat 10. Further, by blowing a gas having a wind pressure and a flow rate that can blow off the water to the fiber mat 10 containing water, the water can be drained from the fiber mat 10 by the wind pressure. Further, the fiber mat 10 containing water is housed in the rotating body or fixed to the side surface of the rotating body, and then the rotating body is rotated to drain water from the fiber mat 10 by centrifugal force. Can be done. These various drainage methods (dehydration methods) may be used alone or in combination of two or more.
Further, the cleaning step R2, the drainage step R3, and the heating step A (R4) are set as one set, and this set may be performed only once, but may be performed a plurality of times of two or more times.

The above-mentioned "heating step B (R6)" (see FIG. 6) is a step of heating the fiber board 20 at a temperature not exceeding the melting point of the thermoplastic resin. That is, it can be rephrased as a fiber board heating process. By providing this heating step B (R6), it is considered that the causative component that induces fogging is volatilized.

The heating temperature in the heating step B (R6) may be any temperature that does not exceed the melting point of the binder resin 20b, and the specific temperature is not limited, but is preferably 50 ° C. or higher, more preferably 60 ° C. or higher. It is preferable, and more preferably 70 ° C. or higher. On the other hand, the upper limit of the temperature at the time of heating is not limited, but for example, 150 ° C. or lower is preferable, 120 ° C. or lower is more preferable, 100 ° C. or lower is further preferable, and 90 ° C. or lower is particularly preferable.
This temperature is the atmospheric temperature in the heating environment. That is, when the heating furnace 56 is used, it is the atmospheric temperature in the heating furnace 56.

Further, the heating in the heating step B (R6) is usually heating under non-pressurization. That is, it is preferable to heat in a state where no pressure is applied to the heating atmosphere from the outside. Specifically, heating in an open system, heating under an air flow, and heating in a reduced pressure environment are preferable. This is because in these environments, the volatilized causative components are easily discharged to the outside of the system.
Further, the fiber board 20 may be heated by only one sheet, but can be heated in layers. In this case, for example, 2 to 20 sheets can be stacked and heated, 3 to 15 sheets can be stacked and heated, and 4 to 10 sheets can be stacked and heated.
The heating step B (R6) may be performed only once, or may be performed a plurality of times of two or more times.

Further, the heating time in the heating step B (R6) is not limited, but can be, for example, 15 minutes or more, 30 minutes or more, 1 hour or more, and 12 hours or more. It can be done for more than a day. On the other hand, the upper limit of the heating time is not limited, but can be, for example, one week or less, one day or less, 12 hours or less, and six hours or less. It can be 1 hour or less, and 30 minutes or less.

Further, in the heating step B (R6), it is considered that the causative component is volatilized by heating, but as a result, moisture is also volatilized from the fiber board 20 at the same time by this heating. The fiber board 20 usually contains at least water content equal to or higher than the equilibrium water content. The equilibrium moisture content of the fiber board 20 varies depending on the content ratio of the plant fiber 20a (plant fiber 20a / (plant fiber 20a + binding resin 20b)) and the environment in which the fiber board 20 is placed, but is, for example, 4 to 13%. Is. Therefore, the degree of removal of the causal substance can be indirectly known by observing the water content. From such a viewpoint, the moisture content of the fiber board 20 after the heating step B (R6) is preferably 10% or less, more preferably 5% or less, further preferably 4% or less, and particularly less than 3%. preferable. The water content is a value calculated by "M2 / M1 × 100" when the dry mass of the fiber board is M1 (g) and the mass of the water contained in the fiber board is M2 (g). This moisture content can be measured using, for example, a heat-drying moisture meter.

The method for producing the anti-fog fiber board includes the heating step (A) and the heating step of at least one of the heating steps (B). That is, the heating step may be performed after the mat forming step R1, may be performed after the board forming step R5, or may be performed after both of these steps. Of these, it is preferable to perform the heating step (B) R6 at least after the board forming step R5. The heating step A (R4) and the heating step B (R6) may be performed only once, or may be performed a plurality of times of two or more times.

According to the method for manufacturing the anti-fog fiber board, for example, the proportion of the binder resin contained in the fiber board 20 can be increased. That is, for example, when the anti-fog effect is obtained by suppressing the amount of the resin fiber 10b mixed in the fiber mat 10, the resin fiber 10b can be used as compared with the conventional method by using the method for producing the anti-fog fiber board. Many fiber mats 10 can be used. That is, an interior material having a large proportion of the binder resin 31b can be used. Specifically, for example, when plant fiber / resin fiber = 60/40, it can be changed to plant fiber / resin fiber = 50/50.

Further, according to the method for manufacturing the anti-fog fiber board, for example, the degree of freedom in its utilization can be improved. That is, for example, when an interior material for a vehicle using a fiber board is attached only to a place where the temperature does not become high to obtain an anti-fog effect, the use of this anti-fog fiber board manufacturing method makes it more effective than the conventional method. Therefore, it can be installed even in places with high temperatures. That is, the degree of freedom can be improved by increasing the selection tolerance of the place to be attached. Specifically, for example, when it is attached to a place in the vehicle that does not reach 100 ° C, it can be attached to a place where the temperature may exceed 100 ° C.

The anti-fog fiber board 20 obtained by using the method for producing the anti-fog fiber board may be used for any purpose, but since it has an excellent anti-fog effect, windows (particularly glass windows) It can be suitably used in a vehicle having. More specifically, it can be suitably used in vehicles such as vehicles (automobiles, railroad vehicles, etc.), airplanes, ships, and the like. More specifically, it can be suitably used as an interior material used for these vehicles, a base material (base material layer) constituting the interior material, and the like.

[2] Method for manufacturing anti-fog interior material The method for manufacturing the anti-fog interior material of the present invention is a method for manufacturing an anti-fog interior material having a base material layer in which plant fibers are bonded to each other by a thermoplastic resin. Yes, the heating step C (R7), the heating step D (R8), and the shaping step R10 are provided (see FIGS. 1 to 3 and 7 to 8).
This method can be used not only when a fiber board that has not been subjected to anti-fog treatment is used, but also can be used for the anti-fog fiber board 20 that has already been subjected to anti-fog treatment.

As described above, this method comprises a heating step C (R7). By providing this heating step C (R7), fogging can be effectively suppressed in the present invention. Although the mechanism is not clear, it is considered that the causative component that induces fogging can be removed (partially or completely removed) by the heating step C (R7).

More specifically, the interior material 30 includes a base material layer 31 in which plant fibers 31a are bound to each other by a thermoplastic resin 31b (binding resin 31b). The plant fiber 31a and the thermoplastic resin 31b are as described above. Such a base material layer 31 is formed by utilizing a fiber board. Therefore, if the fiber board has a property of inducing fogging, that property is inherited by the interior material. Therefore, regardless of whether or not the fiber board used as the raw material of the base material layer 31 is for anti-fog, it is used for the interior material 30 after being subjected to anti-fog treatment to suppress fogging. Can be done. That is, if the fiber board is not anti-fog treated, the anti-fog property can be exhibited, and if the fiber board 20 is anti-fog treated, the anti-fog performance can be further improved. can.

The reason for this fogging is as described above. That is, for example, a lubricating component is provided on the surface of the resin fiber for the purpose of improving or improving the slippage between the resin fiber and various devices and jigs for passing the resin fiber until the resin fiber reaches the fiber mat. May be granted. It is considered that one form of fogging is that the lubricating component and its decomposition products volatilize according to the environment, are cooled on the window surface, the wall surface, and the like, and are deposited on the window surface, the wall surface, and the like. In particular, precipitation on the window surface is required to be suppressed because it obstructs the view. The lubricating component required for the formation of the fiber mat can be eliminated once the formation of the fiber mat is completed. Therefore, it is an unnecessary component in the fiber board, and it is considered that fogging can be made less likely to occur by removing it by the heating step C (R7).

The above-mentioned "heating step C (R7)" (see FIG. 6) is a step of heating the fiber board 20 at a temperature not exceeding the melting point of the thermoplastic resin. That is, it can be rephrased as a fiber board heating process. By providing this heating step C (R7), it is considered that the causative component that induces fogging is volatilized.

The heating temperature in the heating step C (R7) may be any temperature that does not exceed the melting point of the binder resin 20b, and the specific temperature is not limited, but is preferably 50 ° C. or higher, more preferably 60 ° C. or higher. It is preferable, and more preferably 70 ° C. or higher. On the other hand, the upper limit of the temperature at the time of heating is not limited, but for example, 150 ° C. or lower is preferable, 120 ° C. or lower is more preferable, 100 ° C. or lower is further preferable, and 90 ° C. or lower is particularly preferable.
This temperature is the atmospheric temperature in the heating environment. That is, when the heating furnace 56 is used, it is the atmospheric temperature in the heating furnace 56.
Further, the heating temperature and the heating time in the heating step C (R7) can be the same as those in the heating step B (R6), but may be different.

The heating in the heating step C (R7) is usually heating under non-pressurization. That is, it is preferable to heat in a state where no pressure is applied to the heating atmosphere from the outside. Specifically, heating in an open system, heating under an air flow, and heating in a reduced pressure environment are preferable. This is because in these environments, the volatilized causative components are easily discharged to the outside of the system.
Further, the fiber board 20 may be heated by only one sheet, but can be heated in layers. In this case, for example, 2 to 20 sheets can be stacked and heated, 3 to 15 sheets can be stacked and heated, and 4 to 10 sheets can be stacked and heated.
The heating step C (R7) may be performed only once, or may be performed a plurality of times of two or more times.

Further, the heating time in the heating step C (R7) is not limited, but can be, for example, 15 minutes or more, 30 minutes or more, 1 hour or more, and 12 hours or more. It can be done for more than a day. On the other hand, the upper limit of the heating time is not limited, but can be, for example, one week or less, one day or less, 12 hours or less, and six hours or less. It can be 1 hour or less, and 30 minutes or less.

Further, in the heating step C (R7), it is considered that the causative component is volatilized by heating, but as a result, moisture is also volatilized from the fiber board 20 at the same time by this heating. The fiber board 20 usually contains at least water content equal to or greater than the equilibrium water content. The equilibrium moisture content of the fiber board 20 varies depending on the content ratio of the plant fiber 20a (plant fiber 20a / (plant fiber 20a + binding resin 20b)) and the environment in which the fiber board 20 is placed, but is, for example, 4 to 13%. Is. Therefore, the degree of removal of the causal substance can be indirectly known by observing the water content. From such a viewpoint, the moisture content of the fiber board 20 after the heating step C (R7) is preferably 10% or less, more preferably 5% or less, further preferably 4% or less, and particularly less than 3%. preferable. The water content is a value calculated by "M2 / M1 × 100" when the dry mass of the fiber board is M1 (g) and the mass of the water contained in the fiber board is M2 (g). This moisture content can be measured using, for example, a heat-drying moisture meter.

The above-mentioned "heating step D (R8)" (see FIGS. 7 and 8) is a step of heating the fiber board 20 that has undergone the heating step C (R7) to a temperature equal to or higher than the melting point of the thermoplastic resin 20b (binding resin 20b). Is. By providing the heating step D (R8), the binder resin 20b constituting the fiber board 20 can be softened, and as a result, the fiber board 20 can be shaped in the shaping step R10.

The heating temperature of the fiber board 20 in the heating step D (R8) is not limited, and can be appropriately set depending on, for example, the material of the binder resin 20b. Specifically, for example, it can be heated to the same temperature as the melting point of the binder resin 20b. Further, it can be heated to a temperature exceeding this melting point. More specifically, for example, it can be heated in a temperature range of 150 ° C. or higher and 280 ° C. or lower. In particular, when polypropylene is used as the binder resin 20b, it is preferably heated to a temperature range of 170 ° C. or higher and 250 ° C. or lower, more preferably 180 ° C. or higher and 240 ° C. or lower, and particularly preferably 190 ° C. or higher and 230 ° C. or lower.

Further, the fiber board 20 may be heated in any way, and for example, it can be heated by passing it through the heating furnace 56 by using a transport device such as a belt conveyor. On the other hand, uncompressed heating allows heating while compressing so that the compressed state of the fiber board 20 is not excessively released. That is, for example, a hot press 58 or the like can be used. That is, by using the hot press 58, the fiber board 20 can be heated in a compressed state sandwiched between two hot plates.

The above-mentioned "forming step (R10)" (see FIGS. 7 and 8) is a step of shaping the fiber board 20 in a heated state through the heating step D (R8). That is, although the fiber board 20 is usually in the shape of a flat plate, it becomes a base material layer 31 by being shaped. The shape is not limited, and it may be a flat plate shape similar to the fiber board 20, but it may have a predetermined uneven shape or a drawn shape.
The shaping step R10 may be performed in any way, and can be performed by, for example, a cold press 59. The molding conditions in the cold press 59 are not particularly limited, but for example, the mold temperature at the time of molding can be 0 ° C. or higher and 70 ° C. or lower, 10 ° C. or higher and 65 ° C. or lower, and 20 ° C. or higher and 60 ° C. or lower. Can be below ° C. Further, the mold clamping time can be 1 second or more and 300 seconds or less, 5 seconds or more and 150 seconds or less, 15 seconds or more and 100 seconds or less, and 30 seconds or more and 60 seconds or less. be able to.

Further, in the shaping step, in addition to performing the necessary shaping for the planar shape, a desired thickness can be obtained at a desired portion. Specifically, it can be controlled by changing the clearance at the time of pressing. That is, in the region where the clearance at the time of pressing is increased, more restraint on the plant fiber by the binder resin 20b is released, and the plant fiber can be compressed and released to form a thick film. On the other hand, in the region where the clearance at the time of pressing is reduced, the release of the restraint on the plant fiber by the binder resin 20b is reduced, and the plant fiber can be formed thin.

In the method for producing an anti-fog interior material of the present invention, the anti-fog interior material 30 can obtain a skin layer 32 bonded to the base material layer 31. The anti-fog interior material 30 provided with the skin layer 32 can be obtained by pressing the fiber board 20 in a heated state and the skin material to be the skin layer 32 so as to overlap each other during cold pressing. In addition, for example, before the shaping step R10, the fiber board 20 in a heated state and the skin material to be the skin layer 32 are laminated through the heating step D (R8) to obtain the laminated product 33. (See FIG. 8). In this case, the shaping step R10 is a step of shaping the laminate 33.

The epidermis material to be the epidermis layer 32 and the epidermis layer 32 may be composed of only one layer or may be composed of two or more layers. When composed of two or more layers, for example, a surface layer having a design surface (for example, woven fabric, knitted fabric, non-woven fabric, natural leather, synthetic leather, resin sheet, coating layer, etc.) and a cushion layer (arranged on the non-design surface side of the surface layer). ), And can be a laminated body. In addition, if necessary, an adhesive layer, a non-woven fabric layer, a ventilation blocking layer and the like can be provided.

The anti-fog interior material 30 obtained by using the method for producing the anti-fog interior material may be used for any purpose, but since it has an excellent anti-fog effect, windows (particularly glass windows) It can be suitably used in a vehicle having a. More specifically, it can be suitably used in vehicles such as vehicles (automobiles, railroad vehicles, etc.), airplanes, ships, and the like. More specifically, it can be used for these vehicles, that is, an interior material for a vehicle having anti-fog property, an interior material for an airplane having anti-fog property, an interior material for a ship having anti-fog property, and the like.
Among these, for example, vehicle interior materials having antifogging properties include instrument panels, door trims, package trays, pillar garnishes, switch bases, quarter panels, armrests, seats, seat backboards, ceiling materials, console boxes, and dashes. Examples include boards and deck trims. Only one of these may be used, or two or more thereof may be used in combination.

Hereinafter, the present invention will be specifically described with reference to Examples.
[1] Fabrication of fiber board (1)
As plant fibers, kenaf fibers (average fiber length 70 mm, fineness 4 to 10 dtex) were prepared. Kenaf fiber is a plant fiber obtained by defibrating the bast taken out from kenaf by a letting treatment.
As the resin fiber, a fiber made of a non-modified polyolefin resin (homopolypropylene resin, melting point 165 ° C.) (average fiber length 50 mm, with lubrication component attached) was prepared.
The kenaf fiber and the resin fiber were laminated using a card machine to obtain a fiber web (fiber aggregate) having a mass ratio of the kenaf fiber and the resin fiber of 60:40.
The obtained fiber web was heated to 200 ° C. and then cooled to 25 ° C. (cooling press) while pressing to obtain a fiber board 20 having a thickness of 2.4 mm and a basis weight of 1.0 kg / m ² .

[2] Heating step B (R6)
The fiber board 20 obtained in the above [1] was placed in a heating furnace 56 (with an internal ventilation function), the set temperature was set to 80 ° C., and heating was performed for 24 hours. This heating corresponds to the heating step B (R6).

[3] Evaluation of fogging characteristics (1)
The test piece (about 5 g) of Comparative Example 1 cut out from the fiber board not subjected to the heating step B (R6) obtained in the above [1] and the heating step B (R6) obtained in the above [2]. The test piece (about 5 g) of Example 1 cut out from the provided fiber board was evaluated for fogging characteristics according to ISO6452 by using a glossiness measuring method.

Using the apparatus shown in FIG. 9, the tall beaker 42 into which the test pieces 41 of Example 1 and Comparative Example 1 were charged was submerged in an oil bath 43 having a temperature of 100 ° C., and the opening of the tall beaker 42 was closed with a glass plate 44. After 180 minutes have passed while cooling the glass plate 44, the glass plate 44 was removed, and after 4 hours, the glossiness of the surface of each glass plate 44 (gloss meter: manufactured by Suga Test Instruments Co., Ltd., model "UGV" -5DP ") was measured. As a result, it was as follows.
Example 1: Glossiness (reflectance) 94.8%
Comparative Example 1: Glossiness (reflectance) 74.6%

[4] Fabrication of fiber board (2)
The same plant fiber as in [1] above was prepared. Moreover, the same resin fiber as the above [1] was prepared. Then, the resin fiber was passed through hot water having a temperature of 60 ° C., which was 10 times the mass equivalent, and washed with hot water, and then drained. Next, the plant fiber and the resin fiber were mixed at a mass ratio of 50:50 to obtain a fiber board (Example 2). It should be noted that this hot water washing substantially corresponds to the washing step R2, and the hot water draining substantially corresponds to the drainage step R3.
The same plant fiber as the above [1] and the same resin fiber as the above [1] were prepared. Then, the fibers were mixed so as to have a mass ratio of 50:50 to obtain a fiber board (Comparative Example 2).
Similarly, the same plant fiber as in the above [1] and a resin fiber different from the resin fiber in the above [1] only in that the lubricating component is not attached are prepared. Then, a fiber board (Comparative Example 3) mixed so as to have a mass ratio of 50:50 was obtained.

[5] Evaluation of fogging characteristics (2)
In the same manner as in the above [3], each glass using the fiber board of Example 2 (about 6 g), the fiber board of Comparative Example 2 (about 6 g), and the fiber board of Comparative Example 3 (about 6 g). The glossiness of the surface of the plate 44 was measured. As a result, it was as follows.
Example 2: Glossiness (reflectance) 94.3%
Comparative Example 2: Glossiness (reflectance) 58.8%
Comparative Example 3: Glossiness (Reflectance) 91.3%

The present invention is widely used in the field of vehicle reams and the like. More specifically, it is widely used in vehicle-related fields such as automobiles, ship-related fields, aircraft-related fields, construction-related fields, and the like. The anti-fog fiber board and the anti-fog interior material obtained by the present invention are suitable as interior materials, exterior materials, structural materials and the like in the above fields. Among the above-mentioned vehicle-related fields, examples of automobile supplies include automobile interior materials, automobile instrument panels, automobile exterior materials, and the like. Specifically, door base materials, package trays, pillar garnishes, switch bases, quarter panels, armrest cores, automobile door trims, seat structural materials, seat backboards, ceiling materials, console boxes, automobile dashboards, etc. Instrument panels, deck trims, bumpers, spoilers, cowlings and the like. Further, for example, interior materials such as buildings and furniture, exterior materials and structural materials may be mentioned. That is, door surface materials, door structural materials, surface materials for various furniture (desks, chairs, shelves, chests of drawers, etc.), structural materials, and the like can be mentioned. In addition, a package, an accommodating body (tray, etc.), a protective member, a partition member, and the like can be mentioned.

10; fiber mat, 10a; plant fiber, 10b; binder resin,
11A, 11B; web (coarse web), 11C; laminated web,
20; fiber board, 20a; plant fiber, 20b; binder resin,
30; Interior material,
31; base material layer, 31a; plant fiber, 31b; binder resin,
32; Epidermis layer (epidermis material),
33; Laminate,
41; measurement sample, 42; tall beaker, 43; oil bath, 44; glass plate,
51; Needle punch machine,
52; Cutting machine,
53; Plate-shaped net body (wire mesh),
54; aquarium,
55; water,
56; Heating device (heating furnace),
57; Hot pressing machine,
58; Hot press machine,
59; Cold press,
R1; mat forming process,
R2; cleaning process,
R3; drainage process,
R4; heating step A,
R5; board forming process,
R6; heating step B,
R7; Heating step C,
R8; heating step D,
R9; Laminating process,
R10; shaping process.

Claims (8)

A method for manufacturing an anti-fog fiber board to suppress fogging.
A board forming step of heat-compressing a fiber mat in which a plant fiber and a resin fiber containing a thermoplastic resin are mixed to obtain a fiber board in which the plant fibers are bound to each other by the thermoplastic resin. ,
A method for producing an anti-fog fiber board, which comprises at least one of the following heating steps (A) and the following heating step (B).
Heating step (A): Fiber mat heating step of heating the fiber mat at a temperature not exceeding the melting point of the thermoplastic resin Heating step (B): The fiber board at a temperature not exceeding the melting point of the thermoplastic resin. Fiber board heating process to heat The antifogging agent according to claim 1, wherein the moisture content of the fiber mat after the heating step (A) is 10% or less, and the moisture content of the fiber board after the heating step (B) is 10% or less. How to make a fiber board. The method for producing an antifogging fiber board according to claim 1 or 2, further comprising a washing step of washing the fiber mat with water before the heating step (A). The method for producing an anti-fog fiber board according to claim 3, wherein the temperature of the water is 50 to 70 ° C. The fiber board for reducing fogging according to claim 3 or 4, further comprising a drainage step of reducing the moisture content of the fiber mat to 15 to 25% without heating after the washing step and before the heating step (A). Production method. It is a method of manufacturing anti-fog interior materials to suppress fogging.
The anti-fog interior material includes a base material layer in which plant fibers are bonded to each other by a thermoplastic resin.
The heating step (C) of heating the fiber board to be the base material layer at a temperature not exceeding the melting point of the thermoplastic resin, and
The heating step (D) of heating the fiber board that has undergone the heating step (C) to a temperature equal to or higher than the melting point of the thermoplastic resin is used.
A method for producing an anti-fog interior material, which comprises a shaping step of shaping the fiber board in a heated state through the heating step (D). The anti-fog interior material includes a skin layer bonded to the base material layer, and the anti-fog interior material has a skin layer.
Prior to the shaping step, a laminating step of laminating the fiber board in a heated state and the epidermis material to be the epidermis layer to obtain a laminate through the heating step (D) is provided.
The method for manufacturing an anti-fog interior material according to claim 6, wherein the shaping step is a shaping step for shaping the laminate. The method for producing an anti-fog interior material according to claim 6 or 7, wherein the moisture content of the fiber board after the heating step (C) is 10% or less.

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